Microfabricated lenses, methods of manufacture thereof, and applications therefor

ABSTRACT

Microfabricated lenses, e.g., solid immersion lens (SIL) structures, are provided along with techniques for constructing these lens structures, as well as selected applications of such lens structures.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. patent application Ser. No.60/329,469, filed Oct. 8, 2001, which is hereby incorporated byreference in its entirety.

TECHNICAL FIELD

The present invention relates to microfabricated lenses, e.g., solidimmersion lens (SIL) structures, and in particular to techniques forconstructing these lens structures, as well as selected applications ofsuch structures.

BACKGROUND OF THE INVENTION

Lenses are used to focus light in a variety of applications. Forexample, micro-structures, such as cells, are observed with lightfocused in microscopes. Lenses focus light by bending it according tothe law of refraction. The law of refraction states that the change inangle (refraction) of a light ray as it passes from one material intoanother material is related to a material property called the index ofrefraction and the angle the light makes with the interface between thetwo materials. The index of refraction is a measure of the speed oflight in the material. Lenses that are used in microscopes arespecifically designed to bend light which has been reflected by smallspecimens so that their images appear magnified.

Lenses that are used in microscopes are normally at least a fewmillimeters away from the specimen. Light from the lens travels throughair before being focused on the specimen that is to be imaged. Becauseair has a relatively low index of refraction, the degree of featuresthat can be seen on the specimen is limited. In view of this, oil, whichhas a medium index, is placed between the microscope lens and thespecimen. This change in the index of refraction of the medium permitsslightly smaller features to be seen on the specimen relative to thosefeatures on the specimen that are seen when air is the medium. This iscalled oil immersion microscopy.

In order to achieve even greater performance, light is focused through ahigh-index solid held in contact with the specimen. This is called solidimmersion microscopy. In order to produce a suitable solid immersionlens, the lens must have a high index of refraction. One possiblematerial for constructing this type of lens is silicon, whose index ofrefraction is approximately 1.41 as compared to 1.00 for air. Inaddition, the solid immersion lens must be held in contact with thespecimen under examination without causing damage to specimens, such ascells.

Due to the limitations on resolutions obtainable with conventionaloptical lenses for applications such as microscopy, techniques have beendeveloped to decrease the Rayleigh limit on transverse resolution d. TheRayleigh limit is generally understood as being the minimum distancethat two particles may be separated and still be distinguished. TheRayleigh limit is given by δ=0.82λ/(NA) where λ is the wavelength and NAis the numerical aperture of the focusing objective (NA=n sin(θ), wheren is the refractive index of the medium, and θ is the angle between theoutermost rays focusing on the sample and the optical axis). Generally,the numerical aperture is a measure of the resolving power of themicroscope objective. It is a measure of the optical performance of thesystem and concerns the specific ability to differentiate small featuresand the light gathering capability of the system. Whether the NA isconsidered to be low or high depends upon the type of optical systemthat is being used. For example, a high NA for a high powered microscope(e.g., 60× objective oil immersion lens) would be about 1.40.

Coherent light such as laser light can be used to precisely control thewavelength of illumination λ. One way to decrease the transverseresolution is to increase the index of refraction of the optical medium,such as by use of oil-immersion microscopy or use of a solid immersionlens.

If an SIL is placed in contact with the sample under examination,illumination can be more readily focused on it, and use of the high NAof the system allows efficient collection of the excitation light withhigh optical transmission efficiency and observation of the sample witha very high resolution. In most of the cases, the SIL is used primarilyfor near-field microscopy, where the air gap between the SIL and thesample oblige those who do not want to use evanescent waves to work witha NA smaller than one.

A problem with the SIL technology is the complexity of its manufacture.For example, a polished glass sphere provided with a sequence ofprogressively finer alumina powders, requires a polishing time typicallyof many hours. Furthermore, the result is not perfect, and the polishedsurface is slightly rounded. Moreover, known lens structures in SILconfigurations involve objective lens sets that are self contained andthus are difficult to use in a manner that maintains the lens inimmersion contact with the object under observation.

What is needed is a method for simple, inexpensive and rapidconstruction of microfabricated lenses, including solid immersionlenses, and a lens structure which is suited for low-cost, evendisposable usage and for micro-size applications which conventionallenses have been unable to achieve.

SUMMARY OF THE INVENTION

Mircofabricated lenses, such as a solid immersion lens structure, areformed of an optically clear low temperature moldable material such anelastomer cast to a desired shape and smoothness in a pliant mold whichhas highly undercut margins. The level that the margins are undercutwill vary from application and depends upon the type of lens structurewhich is to be formed from the mold. As the margins are undercut moreand more, the lens that is to be formed has a more defined hemisphericalshape.

Further, an exemplary method for construction of a microfabricated lens,such as a solid immersion lens structure or a meniscus type lens,includes providing a pliant mold defining a lens-shaped cavity in whichthe lens is cast, casting a liquid material into the lens cavity,permitting the liquid material to set to form the lens portion of thelens and removing the lens portion from the pliant mold. A specificmaterial for use in forming the microfabricated lens is athermally-resilient deformable material such as optically-clear siliconelastomer of a refractive index n greater than 1.2 and preferablygreater than 1.4, such as a room temperature vulcanization (RTV)elastomer, specifically General Electric RTV 615. Preferably, the molditself may be constructed of this material and the microfabricated lensstructure can be a rigid setting material. The lens structures producedaccording to the exemplary molding method can be a disposable lenselement and/or a light collection element integrated with a specimencarrier of a microfabricated flow cytometer, just to name a few of themany potential applications for the microfabricated lenses.

Two microfabricated lenses that are of particular interest are a solidimmersion lens having improved light collection/focusing properties anda lens of a meniscus type. Advantageously, the present manufacturingprocess yields inexpensive optical elements, such as an SIL lensstructure, as compared to conventional lenses. Further, the lens portionof the SIL lens structure is integrally formed with the sample carrierand this permits the complete SIL lens structure to be disposable. Themeniscus type lens has a lens portion which has a convex surface on oneside and a concave surface of the other side. As with the SIL lensstructure, the meniscus type lens is configured to have improved opticalproperties as a result of the present manufacturing process. The lensportion of the meniscus type lens is configured to capture a very largesolid angle of illumination and acts to further and more completelyredirect light to a detection element or the like. The meniscus typelens is particularly tailored to be used in combination with the SILstructure and this lens combination results in the enhancement of thenumerical aperture (NA) of the optical system.

Further according to the invention, a method is provided for imaging anobject using a low cost lens element in an SIL configuration. Accordingto this method, an object to be observed, preferably immersed in fluid,is guided along a passage defined by an integrally molded-together bodyportion and a solid immersion lens portion, where the solid immersionlens portion is optically aligned with a position in the passage. Theobject is positioned in the passage in alignment with the solidimmersion lens portion so that the object is within a field of viewextending through the spherical solid immersion lens portion. Theobject, immersed in a fluid of high index of refraction, is viewedthrough the spherical solid immersion lens portion of an even higherindex of refraction, and the object is imaged onto a viewing surface.The combined use of the SIL lens structure with the meniscus type lensfurther enhances the imaging performance of the optical system.

One exemplary imaging system that illustrates the benefits provided byusing an optical system incorporating the SIL lens structure and themeniscus type lens is a miniature microscope that is integrally formedwith a micro-sized workstation, i.e., a microfluidic chip. In such anapplication, a miniature monolithic optical system is constructed andincludes not only the SIL lens/meniscus type lens combination but alsoother ordinary lenses. These ordinary lenses are preferably formed usinga molding process similar to that which is used to form SIL lensstructure and the meniscus type lens. The ordinary lenses can be of anynumber of constructions (e.g., convex, concave, piano-convex, etc.) andhave a variety of dimensions. The SIL lens structure is aligned withrespect to one of micro-channels formed in the microfluidic chip and themeniscus type lens is aligned with respect to the SIL lens structure.Other lenses are then arranged so that light from source is focused ontoan observation region (i.e., a micro-channel) of the SIL lens structure.The configuration of the SIL lens structure acts to enhance thenumerical aperture and the mensicus type lens acts to even greaterenhance the numerical aperture (NA) due to its construction and itspositioning relative to the SIL lens structure. An imaging systemconstructed in this manner is characterized as having greatly improvedresolution and magnification as compared to conventional lens systems.

Further, a method is provided for collecting light emissions with highefficiency through a low cost lens element in an SIL configuration. Anobject to be observed is immersed in fluid and positioned in alignmentwith the solid immersion lens portion so that the object is within afield of light collection extending through very large numericalaperture spherical solid immersion lens portion. The object, immersed ina fluid of high index of refraction, emits observable optical energytypically by fluorescence in response to excitation, and the emissionsat selected wavelengths are collected through the spherical solidimmersion lens portion of an even higher index of refraction anddirected to a sensor, typically without imaging, so that the emissionscan be measured. The structure admits to high collection efficiency.Once again, the use of the meniscus type lens in combination with theSIL lens structure further enhances the obtained benefits.

The invention will be better understood by reference to the followingdetailed description and the accompanying diagrammatic drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic cross-sectional view of a solid immersion lensstructure according to one embodiment;

FIG. 2 shows a schematic three-dimensional view of an initial step in amethod for producing a solid immersion lens structure in accordance witha first embodiment;

FIG. 3 shows a cross-sectional view corresponding to FIG. 2 indicatingfurther steps of producing a solid immersion lens structure;

FIG. 4 shows a cross-sectional view corresponding to FIG. 3 showing asubsequent step in a method of producing a solid immersion lensstructure;

FIG. 5 shows an imaging system comprising a solid immersion lensstructure in accordance with one embodiment;

FIG. 6 shows an emission collection system comprising a solid immersionlens structure in accordance with one embodiment;

FIG. 7 shows a schematic cross-sectional view of a solid immersion lensstructure according to another embodiment;

FIG. 8 shows a cross-sectional view of an initial step in a method forproducing a solid immersion lens structure in accordance with a secondembodiment;

FIGS. 9-11 show cross-sectional views illustrating further steps forproducing the solid immersion lens structure after the step of FIG. 8 isperformed;

FIG. 12A shows an enlarged cross-sectional view of a section of FIG. 11illustrating the height of a layer of material around a mold core;

FIG. 12B shows a calibration curve graph for determining a pre-curinggraph for determining a pre-curing time period based upon the selectedheight of the material;

FIGS. 13-16 show cross-sectional views of further steps for producingthe solid immersion lens structure after performing the step of FIG. 11;

FIG. 17 shows a schematic cross-sectional view of a solid immersion lensstructure of a meniscus type;

FIG. 18 shows a cross-sectional view of an initial step in a method forproducing a lens of the type shown in FIG. 17;

FIGS. 19-21 show cross-sectional views illustrating further steps forproducing the meniscus type lens after the step of FIG. 18 is performed;

FIGS. 22A-22C show sequential steps for producing a spacer layer used inthe method for producing the meniscus type lens shown in FIG. 17;

FIGS. 23-28A show cross-sectional views illustrating further steps forproducing the meniscus type lens after the steps of FIGS. 22A-22C areperformed;

FIG. 28B shows an enlarged cross-sectional view of a section of FIG. 22Afrom which the meniscus type lens of FIG. 17 is formed;

FIG. 28C shows a cross-sectional view of another embodiment of ameniscus type lens of the type shown in FIG. 17 used in combination withthe solid immersion lens structure of FIG. 7;

FIG. 29 shows a cross-sectional view of a lens system including thesolid immersion lens structure of FIG. 7 in combination with themeniscus type lens of FIG. 17;

FIG. 30 shows a cross-sectional view of an integrated imaging systemaccording to one embodiment;

FIG. 31 shows a cross-sectional view of an initial step in a method forproducing a lens structure of another type and for use in the integratedimaging system of FIG. 30;

FIGS. 32-37 show cross-sectional views illustrating further steps forproducing the lens structure after the step of FIG. 31 is performed;

FIG. 38 shows a cross-sectional view of an initial step in analternative method for producing a lens structure of yet another typeand for use in the integrated imaging system of FIG. 30;

FIGS. 39-43 show cross-sectional views illustrating further steps forproducing the lens structure after the step of FIG. 38 is performed;

FIG. 44 shows a ray diagram for an SIL lens combined with a meniscustype lens;

FIG. 45 shows a ray diagram for the combined lenses of FIG. 44 alongwith additional lenses positioned thereto;

FIG. 46 shows a perspective view of a microfluidic device having anintegrated imaging system;

FIG. 47 shows a cross-sectional of an initial step in a method forproducing an array of molded lenses;

FIGS. 48-52 show cross-sectional views illustrating further steps forproducing the array of molded lenses after the step of FIG. 47 isperformed;

FIG. 53 shows a perspective view of an array of molded lenses producedaccording to the method of FIGS. 47-52;

FIG. 54 shows a schematic diagram showing an exemplary imaging systemincorporating an SIL lens;

FIG. 55 shows a graph showing the excitation range and emission range ofthe system of FIG. 54;

FIGS. 56A and 56B show light intensity profiles of samples when an SILis used in the system of FIG. 54 and when it is not used;

FIG. 57 shows a graph illustrating total intensity of the objects withand without the use of the SIL lens; and

FIG. 58 shows a graph illustrating the average ratio of two lightintensities.

DESCRIPTION OF SPECIFIC EMBODIMENTS

In order to understand the invention, it is helpful to define the termsassociated with a solid immersion lens SIL structure 50 as it might beused in a device such as a microscope, spectroscope or cytometer. FIG. 1illustrates the functioning of a solid immersion lens, with indicationof the parameters used to describe the structure and operation. A solidimmersion lens portion 51 comprises a sphere of radius r and index ofrefraction n_(s). It is disposed at a highest height h above a surface27 of a body portion 28 so that a boundary margin 25 is formed which isnarrower in diameter than the diameter of the lens portion 51. Anobservation region 52 is provided at a distance h′ from the surface 27.Samples are placed in the region for observation according to theintended application, such as microscopy, spectroscopy or cytometry.Also shown with the structure 50 is a collection/collimating lens 150.The spherical structure and collection configuration admits toconstruction of lens systems having a numerical aperture higher thanunity, which is particularly useful for ultrasensitive spectroscopy.

A method for producing a solid immersion lens structure in accordancewith the invention is described with reference to FIGS. 2-4. Referringto FIG. 2, a container 10, typically in the form of a shallow dishdefining a base wall 12 and four peripheral upstanding sidewalls 14provides the housing for a mold. To produce the solid immersion lensstructure in accordance with the method of the invention, a mold isformed. To form the mold, a first layer 16 of moldable material fromwhich the mold is to be formed is cast into the container 10. The firstlayer 16 is then permitted to set. Referring now to FIG. 3, once thefirst layer 16 has set, a mold core 18 is positioned in the container 10on the first layer 16. In this instance the mold core is a sphericalbead of uniformly smooth surface, such as a steel bead of radius r=˜0.8mm-4.5 mm. A second layer 20 of moldable material is then cast into thecontainer of height h=˜1 mm-5 mm partially to encapsulate the mold core18, thereby to form a second layer of moldable material 20 immediatelyadjacent the first layer 16. The second layer 20 defines an uppersurface 22 at height h such that an upper portion 18.1 of the generallyspherical mold core 18 protrudes through an orifice 23 of diameter dfrom the upper surface 22 and creates highly undercut margins 25 aroundthe orifice 23. In order for the mold to be reusable where the structurehas such undercut margins, the second layer, according to the invention,must be of a pliant material such as a silicon elastomer, such as a roomtemperature vulcanization (RTV) elastomer, specifically General ElectricRTV 615.

The constraint on the height h is given by the following relation (I):r(1−cos φ)<h<r+r/n _(s)where

-   -   r is the radius of the sphere,    -   h is the height of the layer,    -   Φ is the polar angle from the center of the sphere to the edge        of the orifice formed by the undercut margins,    -   n_(s) is the index of refraction of the material which forms the        lens.

Thus the geometric details of the mold depend upon the thickness of thesecond layer 20 relative to the radius of the bead. The RTV an elastomermade by mixing polymers, cross linkers and a catalyst. While it cures atroom temperature, it is typically set for two hours at a slightlyelevated temperature of 80° C. The preferred RTV comprises a first partof a polydimethylsiloxane bearing vinyl groups and a platinum catalystand a second part of a cross linker containing silicon hydride (Si—H)groups. Once mixed, the silicon hydride groups form a covalent bond withthe vinyl groups.

Referring to FIG. 4, once the layer 20 has set, the mold core 18 isremoved so as to define a lens cavity 24. In this manner, a mold 26 forproducing a solid immersion lens structure, in accordance with theinvention, is produced. To minimize the chance of bonding between themold and the lens, the surface is treated with an oxygen plasma to forman anti-adhesive layer 27. For example, oxidized RTV blocks bonding sothe molded lens can be removed from the lens cavity 24.

Still referring to FIG. 4 and to FIG. 1, the solid immersion lensstructure 50 is produced by casting a moldable material into the lenscavity 24. The moldable material from which the solid immersion lensportion of the solid immersion lens structure is to be formed istypically cast into the container 10 to fill not only the lens cavity24, but also to form a layer 28 in the container 10, the layer 28defining an upper surface 28.1 above (as shown) the lens cavity 24. Thethickness h′ above the surface 27 is given by the relation (1A):h′=r+r/n _(s) −h.

The layer 28 forms a body portion of the solid immersion lens structure50 when the moldable material of layer 28 has set. In this manner, thebody portion of the solid immersion lens structure is integrally moldedtogether with the solid immersion lens portion 51.

When the layer 28 has set, the solid immersion lens structure inaccordance with the invention, which includes a body portion 30 and asolid immersion lens portion 32 is formed. The solid immersion lensstructure is then removed from the mold.

The material from which the SIL structure 50 is made in mold 26 may beof any suitable optically clear material that can be cast as a liquid ata temperature less than the temperature at which the mold 26 is damagedor otherwise undesirably deformed. The SIL structure may cure to agenerally rigid solid or a pliant solid. Among the materials consideredto be generally suitable are low temperature of formation polymers, roomtemperature vulcanization elastomers, low temperature of formationepoxies, polyimides, polycarbonates and photoresists. The lens material50 can be a pliant silicon elastomer. A suitable silicon elastomer isGeneral Electric RTV 615, the same material used to create the mold 26itself.

As is clear from FIG. 4, the lens cavity 24 has a transverse dimensiongreater than the traverse dimension of a orifice 23 of the cavity 24.The moldable material from which the mold 26 is made is deformable sothat when the moldable material from which the solid immersion lensstructure 50 in accordance with the invention is made, has set, and isremoved from the mold 26, a region of the mold 26 adjacent the mouth ispermitted to deform thereby to permit the solid immersion lens portionto pass therethrough.

Referring now to FIG. 1, a solid immersion lens structure, generallyindicated by reference numeral 50, is indicated. The structure 50 hasbeen formed in accordance with the method of the invention as describedabove with reference to FIGS. 2-4 of the drawings. In addition, thestructure 50 has been formed to define a sample observation region 52 ina passage extending therethrough. This passage may be formed in anysuitable manner, such as by positioning an elongate mold core in thelayer 28, with reference to FIG. 4, prior to the moldable materialdefining layer 28 having set. The elongate mold core from which thepassage 52 is formed can be of a material which disintegrates whenexposed to a suitable agent. Accordingly, when the structure 50 has beenformed, the core can be removed by exposing it to the suitable agentthereby to remove the core from the structure 50 and to yield the hollowregion 52. Alternatively, the region 52 can be formed in any one of theways described in Applicants' co-pending patent application No. Ser. No.09/605,520 filed Jun. 27, 2000. For example the region 52 can be formedas part of a two-step construction process whereby the height h′ isprecisely defined during the first step and then the passage and a bodyportion is added as a second step.

FIG. 5 is illustrative of an imaging system 100 employing an SIL 50 inaccordance with the invention. An example is a microscope. The systemincludes a laser 110 projecting a beam 111, an expansion lens 112, afirst collimating lens 114, a partially transmissive mirror 116, asecond collimating lens 118, an SIL structure 50, a focusing lens 120,an image detector such as a CCD camera 124 and a control apparatus 123.In operation, the laser 110 projects an illumination beam 111 throughexpansion lens 112 and collimating lens 114 to produce a broad coherentmonochromatic illumination beam 115. The beam 115 is reflected by mirror116 to second collimating lens 118 through which it is focused throughan air medium to the SIL structure 50. Focus adjustment is by means ofpositioning of the second collimating lens 118 relative to the SILstructure 50. The SIL structure 50 further focuses to a spot in thesample chamber (not shown) within the body portion, in immersion contactwith the lens. The sample is positioned by the control apparatus 123.(The control apparatus 123 may both position a platform and supply theobject or sample to be viewed.) Light reflected from the object isdirected back through the second collimating/focusing lens 118 whichfocuses to infinity and directs the image 119 through the half silveredmirror 116 to a third focusing/collimating lens 120. The thirdfocusing/collimating lens 120 focuses the image as magnified onto animage sensor 124, such as a CCD array of a CCD camera. The relativepositioning of the lens 120 and the image sensor 124 determines focus ofthe image. Other microscope configurations may be employed as suggestedby this configuration. Significantly, the SIL structure 50, although anessential element of the optical system is obtained from a manufacturingprocess which yields extremely inexpensive optical elements as comparedto conventional lenses, so the SIL structure 50, which is integral withthe sample carrier, is disposable. This is believed to be a significantadvance over conventional SIL technology. This also presents significantpractical advantages over methods using oil immersion objectives. It isnot necessary to use oil between the lens and sample since they areintegrally molded. In addition, an oil immersion objective must bepositioned with high accuracy with respect to the sample. However, asolid immersion lens can be fabricated as the appropriate distance awayfrom the sample so that focal precision would be needed to adjust thedistance between an oil immersion lens and the sample.

FIG. 6 is illustrative of a light collection system 200 employing an SIL50 in accordance with the invention. An example is a cytometer or ahighly efficient spectrometer. The system 200 includes a laser 210projecting a beam 211, an expansion lens 212, a first collimating lens214, an optional first dichroic filter 217 selected for passing theselected output wavelength of the laser 210, a partially transmissivemirror 216, a second collimating lens 218, an SIL structure 50, a seconddichroic filter 219 selected for passing the selected emission of thesample, a collection lens 220, a photon collection device such as aphotomultiplier tube 226 and a control apparatus 223. In operation, thelaser 210 projects an illumination beam 211 through expansion lens 212and collimating lens 214 to produce a broad coherent monochromaticillumination beam 215. Its purity is further selected by filter 217 sothat the illumination can be used as an excitation probe. The beam 215is reflected by mirror 216 to second collimating lens 218 through whichit is focused through an air medium to the SIL structure 50. Focusadjustment is by means of positioning of the second collimating lens 218relative to the SIL structure 50. However, as an emission collectionapparatus, imaging is not the goal. The SIL structure 50 furtherconcentrates the illumination to in the sample chamber (not shown)within the body portion, in immersion contact with the lens. The sampleis excited by the illumination and positioned by the control apparatus223. (The control apparatus 223 may both position a platform and supplythe object or sample to be viewed.) The illumination excites the sampleto cause it to emit fluorescent energy which is collected by the highnumerical aperture lens and is directed back through the secondcollimating lens 218 which focuses to infinity and directs the emittedphotonic energy through the half silvered mirror 216 to the secondfilter 219, which blocks any stray excitation, and then through thethird collimating lens 220. The third collimating lens 220 concentratesthe photonic energy into a collection region of a photon sensor such asa photomultiplier tube (PMT) 226. The relative positioning of the lens120 and the PMT 226 the collection efficiency. This application isbelieved to be a new application of an SIL structure. Otherconfigurations may be employed as suggested by this configuration.Significantly, the SIL structure 50, although an essential element ofthe optical system is obtained from a manufacturing process which yieldsextremely inexpensive optical elements as compared to conventionallenses, so the SIL structure 50, which is integral with the samplecarrier, is disposable. This is believed to be a significant advanceover conventional SIL technology.

With reference to FIG. 7, a solid immersion lens SIL structure 300according to another exemplary embodiment is illustrated. The SILstructure 300 is essentially identical to the SIL structure 50 in themanner that it functions as a solid immersion lens. The SIL structure300 includes a solid immersion lens portion 302 in the form of a sphereof radius r and index of refraction n_(s). The solid immersion lensportion 302 is disposed at a highest height h₁ above an upper surface304 of a body portion 306 so that a boundary margin 308 is formed. Theboundary margin 308 is narrower in diameter than the diameter of thelens portion 302. An observation region 310 is formed in the bodyportion 306 and is preferably centrally located underneath the lensportion 302. The observation region 310 is formed at a distance h₂ fromthe upper surface 304. Samples, i.e., specimens, are placed in theobservation region 310 according to the intended application of the SILstructure 300. Exemplary applications include but are not limited tomicroscopy, spectroscopy, cytometry, and in one particular application,which will be described in great detail hereinafter, the SIL structure300 forms a part of a miniature microscope which is adapted to beintegrated into a microfluidic workstation.

The observation region 310 can be in the form of a transverse passageprovided in the body portion 306 such that a portion of the passageextends underneath the lens portion 302 so that a sample in the passagecan be positioned directly underneath the lens portion 302. In thisembodiment, the passage includes an inlet leading into the passage andan outlet leading from the passage. A liquid supports an object 312 inthe passage with the liquid being pumped or otherwise directed throughthe inlet and along the passage causing the object 312 to pass throughthe inlet and along the passage in the direction of the z-axis. Theliquid is then discharged through the outlet.

The SIL structure 300 is designed so that it can be used in combinationwith other lenses in an optical system. For example, FIG. 7 illustratesthe SIL structure 300 being used in combination with acollection/collimating lens 320. The spherical structure of the SIL 300and the illustrated collection configuration admits to construction of alens system having a numerical aperture higher than unity. This isparticularly advantageous and useful for ultrasensitive spectroscopy.

A method for producing the SIL structure 300 is described with referenceto FIGS. 8 through 16. Referring to FIG. 8, a substrate 330 is providedand includes a first surface 332 and an opposing second surface 333. Thefirst surface 332 should be of a planar construction and in oneexemplary embodiment, the substrate 330 is a silicon wafer or otherrigid structure. The substrate 330 functions as a foundation forfabrication of a mold which is used to form the SIL structure 300.Preferably, the substrate 330 undergoes conventional cleaning operationsto ensure that it is of high quality and without foreign matter. To formthe mold, a first layer 334 of moldable material from which the mold isto be formed is cast on the first surface 332 of the substrate 330, asshown in FIG. 9. The first layer 334 is preferably formed to have auniform thickness and is free of any imperfections such as bubbles, etc.Suitable techniques, such as spin coating, are preferably used so as tocreate a uniform thickness for the first layer 334 and remove anyimperfections. The first layer 334 is then permitted to set. In oneexemplary embodiment, the first layer 334 is of a pliant material, suchas a room temperature vulcanization (RTV) elastomer. One particularlypreferred RTV is commercially available under the trade name RTV 615from General Electric.

Referring now to FIG. 10, once the first layer 334 has set, a secondlayer 340 of moldable material is cast on the first layer 334. Thesecond layer 340 is preferably formed to have a uniform thickness. Thesecond layer 340 is also formed of a pliant material, such an RTVelastomer, and preferably, the first layer 334 and the second layer 340are formed of material that is supplied from the same source. In oneexemplary embodiment, the first and second layers 334, 340 are formed ofthe same material. For example, General Electric RTV 615 is preferablyused to form the first and second layers 334, 340.

The precise thickness of the second layer 340 depends upon the radius ofa spherical mold core 350 (FIG. 11) that is used to form the mold. Morespecifically, the second layer 340 is formed on the first layer 334 to aheight h₃ so as to partially encapsulate the mold core 350 when the moldcore 350 is positioned in the second layer 340 (See FIG. 12A). In oneexemplary embodiment of FIG. 12A, the height h₃ of the second layer 340is about 260 microns based upon the second layer 340 having an initialthickness of 30 microns and the mold core 350 having a radius of 150microns. It will be understood that the above-recited value of h₃ ismerely exemplary and this value will vary from application toapplication as a function of several parameters, such as the initialthickness of the second layer 340 and the radius of the mold core 350.Furthermore, the constraint on the height h₃ is given by theaforementioned relation (I). Thus, it will be appreciated that thegeometric details of the mold depend upon the thickness of the secondlayer 340 relative to the radius of the spherical mold core 350.Preferably, techniques, such as spin coating, are used when casting thesecond layer 340 on the first layer 334 to ensure that the second layer340 has a uniform thickness.

Referring now to FIGS. 10 and 11, the mold core 350 is positioned byplacing it in a central region of the second layer 340. The mold core350 is preferably a spherical bead of uniformly smooth surface. The moldcore 350 is not limited to having a spherical shape as it can haveanother shape, such as elliptical, etc. The selection of the mold core350 will depend upon the precise application and the radius can be amicro-size (e.g., 150 microns) or it can be a larger value such as 4.5mm or any value therebetween. The spherical mold core 350 may be formedof a number of materials, including steel, sapphire and ruby. Sapphireand ruby micro spheres are available in micro sizes and have been usedin different optics applications, such as fiber coupler and other opticsapplications. Sapphire and ruby spherical beads are both made fromaluminum oxide (Al₂O₃) and their physical and chemical properties areessentially the same. Both have a low coefficient of expansion(8.4*10⁻⁶/°C.), good sphericity (0.64 micron) and a low diametertolerance (+/−2.54 microns). Because the dimensions of the sphericalmold core 350 can be very small, e.g., 150 microns, ruby has oneadvantage in that its red color makes it easier to detect and thereforeeasier to handle.

Upon the positioning of the spherical mold core 350 in the second layer340 prior to the second layer 340 setting, surface tension causes thematerial of the second layer 340 to cover a portion of the sphericalmold core 350. With ever increasing surface tension, the material of thesecond layer 340 will travel further up the spherical surface of themold core 350 toward an upper portion thereof, thereby covering more ofthe surface of the mold core 350.

One aspect of the present mold manufacturing method is intended togreatly reduce or eliminate the disadvantages associated with thesurface tension phenomena. The material forming the second layer 340 issubjected to a pre-curing process. In the pre-curing process, thematerial of the second layer 340 is heated to a predeterminedtemperature and for a predetermined period of time. The polymers of theRTV material are sensitive to temperature and the properties of the RTVmaterial are therefore influenced by heating. The pre-curing processcauses reticulation of polymer chains and a change in the bond structureof the polymers and this results in a change in the viscosity of the RTVmaterial. More specifically, the pre-curing process inducescross-linking into the polymer chains. The polymer chain become largerresulting in it being more difficult to bring the molecules together atthe interference between the liquid polymers and air. This requires moreenergy to be expended and therefore results in a reduction in thesurface tension. By increasing the viscosity of the RTV material, lessmaterial will be drawn to the spherical mold core 350 and therefore lessRTV material covers the spherical mold core 350.

FIG. 12A illustrates a preferred height h₃ of the second layer 340relative to the spherical mold core 350 at the conclusion of thepre-curing process. Because the second layer 340 is used to form themold, as will be described hereinafter, it is desirable that a portionof the second layer 340 encapsulates the spherical mold core 350.Preferably, the second layer 340 is formed to a height h₃ around thespherical mold core 350. One preferred height h₃ is determined accordingto the following relation (II):h=r(1+1/n _(s))where

-   -   r is the radius of the spherical mold core 350,    -   n_(s) is the index of refraction of the material which forms the        lens.

The period of time that the material of the second layer 340 should beheated is dependent upon several parameters, including the type ofmaterial that is being used to form the second layer 340. Calibrationcurves can be empirically generated for different types of materials andone exemplary calibration curve graph is illustrated in FIG. 12B. FIG.12A also illustrates the height h₃ of the second layer 340 relative tothe spherical mold core 350 so that the relationship between thecalibration curves and the height h is more readily illustrated. Thisexemplary calibration curve graph is based on the second layer 340having a thickness of 30 microns. The graph includes a first calibrationcurve 360 and a second calibration curve 370. The first calibrationcurve 360 represents the instance where General Electric RTV 615 is usedas the material of the second layer 340 and the second calibration curve370 represents when Sylgard® silicon is used (commercially availablefrom Dow Corning).

The calibration curves 360, 370 can be used to define the proper periodof time that a given material is to be subjected to the pre-curingprocess described above. The pre-curing process is done prior topositioning of the spherical mold core 350 into the heated material 340.As previously-described, it is desirable for the height h₃ of thematerial to calculated according to the relation (II). In thecalibration curve graph, the y axis represents the height h₃ of thematerial and the x axis represents the period of time that the materialis heated. The initial thickness of the material is predetermined sothat the material will encapsulate a substantial portion of the surfaceof the spherical mold core 350 if the material does not undergo theaforementioned pre-curing process. From this starting point, the timeperiod for the pre-curing process is calculated so that the coveringeffect on the mold core 350 is reduced to a preselected value (i.e.,until a desired h₃). As the material is heated in the pre-curingprocess, less and less of the surface of the mold core 350 is coveredwith the material. As the time period (t) approaches infinity, thecurves will approach the starting thickness of the material (30 micronsin this exemplary embodiment). In other words, as t approaches infinity,the covering effect is essentially eliminated.

Using the applicable calibration curve based upon the precise parametersof the application, the user can easily determine the value of t giventhe desired characteristics of the molding, including the height h₃ ofthe material 340. In one exemplary embodiment, the value of t isdetermined based upon the height h₃ being determined according to therelation (II), namely h=r(1+1/n_(s)). In the exemplary embodimentillustrated by the calibration curve graph of FIG. 12, the value of tfor General Electric RTV 615 is about 2 minutes and 15 seconds and thevalue of t for Slygard® is slightly less than 1 minute.

It will be understood that the calibration curve graph illustrated inFIG. 12B is specific for a second layer 340 having a thickness of 30microns with the material of the second layer 340 either being Sylgard®or General Electric RTV 615. Therefore, other calibration curves can beused if the thickness of the second layer 340 and/or the material itselfare changed. One of skill in the art will appreciate that a number ofcalibration curve graphs can be empirically generated based upon thecontrolling parameters, such as the initial height h of the materialprior to insertion of the spherical mold core 350, the radius of thespherical mold core 350, the type of silicon material used, etc.

Once the desired height h₃ of the second layer 340 has been determined,the material forming the second layer 340 is heated for the time period(t) which is determined by the intersection between (a) a line parallelto the y axis that contains the height h₃ and (b) the respectivecalibration curve. By pre-curing the material for time period (t), whichcorresponds to height h₃ satisfying relation (II), the surface tensionphenomena is controlled. This results in control of the amount of thespherical mold core 350 that is covered with the material uponpositioning of the spherical mold core 330 in the second layer 340. Thispermits proper tailoring of height h₃ of the material 340 relative tothe spherical mold core 350 and more particularly, because the material340 is used to form the mold, this pre-curing process permits the molddimensions to be controlled with enhanced precision. Advantageously,this allows lenses of very precise dimensions (micro size) and profilesto be produced.

Referring to FIGS. 11 and 12, after heating the second layer 340 for theselected time period (t), the spherical mold core 350 is positioned inthe central region of the second layer 340 which is formed over thefirst layer 334 and the substrate 330. Because the first layer 334 isset, the spherical mold core 350 rests upon an upper surface 335thereof. The second layer 340 defines an upper surface 341 at height h₃such that an upper portion 351 of the spherical mold core 330 protrudesthrough an orifice 337 of diameter d from the upper surface 341 andcreates highly undercut margins 308 around the orifice 337. As mentionedhereinbefore, the height h₃ of the second layer 340 is constrained bythe relation (I) and, accordingly, the geometric details of the molddepend upon the thickness of the second layer 340 relative to the radiusof the spherical mold core 350.

In order for the mold to be reusable where the structure has suchundercut margins 308, the second layer 340 is formed of a pliantmaterial and therefore the aforementioned silicon elastomers aresuitable materials. In one exemplary embodiment, an RTV elastomer ismade by mixing polymers, cross linkers and a catalyst. While thismaterial cures at room temperature, it is typically set for a specifiedtime period (e.g., 45 minutes to 2 hours) at an elevated temperature of80° C. One preferred RTV elastomer comprises a first part of apolydimethylsiloxane bearing vinyl groups and a platinum catalyst and asecond part of a cross linker containing silicon hydride (Si—H) groups.Once mixed, the silicon hydride groups form a covalent bond with thevinyl groups.

Referring to FIG. 13, once the second layer 340 has set, the sphericalmold core 350 is removed so as to define a lens cavity 370 (FIG. 14). Inthis manner, a mold for producing a solid immersion lens structure isproduced. To minimize the chance of bonding between the mold and thelens, the surface is treated with an oxygen plasma to form ananti-adhesive layer. Oxygen plasma effectively quenches the reactivefunctions of the silicon second layer 340 and prevent this layer fromsticking to the lens. This permits the lens to be easily removed fromthe lens cavity 370 (FIG. 14). It will be appreciated that other methodsof quenching the reactive functions of the silicon can be used so longas they are suitable for the intended use.

Referring to FIG. 15 and FIG. 7, the solid immersion lens structure 300is produced by casting a moldable material into the lens cavity 370. Themoldable material from which the solid immersion lens portion 302 of thesolid immersion lens structure 300 is to be formed is typically castonto the second layer 340 to fill not only the lens cavity 370, but alsoto form a third layer 390. In this step, the mold is typically placed ina container (not shown), such as a petri dish, to facilitate theformation of the third layer 390. The third layer 390 defines an uppersurface 392 above the lens cavity 370. The third layer 390 forms thebody portion 306 of the solid immersion lens structure 300 when themoldable material of the third layer 390 has set. In this manner, thebody portion 306 of the solid immersion lens structure is integrallymolded with the solid immersion lens portion 302.

When the third layer 390 has set, the solid immersion lens structure300, including the body portion 306 and the solid immersion lens portion302, is formed. The solid immersion lens structure 300 is then removedfrom the mold as shown in FIG. 16. The material from which the SILstructure 300 is made in the mold may be of any suitable optically clearmaterial that can be cast as a liquid at a temperature less than thetemperature at which the mold is damaged or otherwise undesirablydeformed. The SIL structure 300 may cure to a generally rigid solid orpliant solid. As with the SIL structure 50 of the first embodiment, theSIL structure 300 of the second embodiment is preferably formed of lowtemperature of formation polymers, including those listed previouslyherein with reference to the first embodiment. Accordingly, the lensmaterial can be a pliant silicon elastomer, including General ElectricRTV 615, the same material used to create the mold itself.

The moldable material from which the mold is made is deformable so thatwhen the moldable material from which the solid immersion lens structure300 is made, has set, and is removed from the mold, a region of the moldadjacent the mouth is permitted to deform thereby to permit the solidimmersion lens to pass therethrough. Because the mold is formed ofmaterials having the above characteristics, the mold is reusable andthis results in significant cost savings being achieved.

Referring again to FIG. 7, the solid immersion lens structure 300includes the observation region 310 in a passage that extends throughthe structure itself. This passage may be formed in any suitable manner,such as by positioning an elongate mold core in the third layer 390,with reference to FIG. 15, prior to the moldable material defining thethird layer 390 having set. The passage is then formed using the samesteps outlined previously in reference to the formation of passage 52(FIG. 1). In another embodiment, the base portion 306 is actually formedof two sections. A first section is formed separately from the secondsection and includes the section of the base portion 306 that includesthe observation region 310. An upper surface of this first section islocated slightly above the observation region 310 with the secondsection of the base portion 306 including the lens portion 302 and anupper section of the base portion 306 (at least the upper surface 304thereof). The two sections are formed of a pliant elastomer and then areintegrally connected to one another using a suitable process, such asplasma bonding or off ratio combination. As previously-mentioned, onepreferred RTV elastomer is actually formed of two parts which are mixedaccording to a predetermined ratio to form the RTV elastomer. Forexample, one exemplary RTV elastomer is mixed according to a 10:1 ratio(first part: second part) which yields a complete reaction in which allof the reagents are spent. In off ratio combination, the two elastomericlayers that are to be integrally bonded are mixed according to differentratios. For example, the first section of the base portion 306 may bemixed according to a 30:1 ratio, while the second section is mixedaccording to a 5:1 ratio. Both of these off ratio sections contain onereagent in excess so that when the two are place in contact with oneanother and cured, the two contacting interface surfaces of the sectionsbond due to excess reagents being present at these surfaces.

The following example illustrates one exemplary process for producingthe SIL lens structure 300 according to one embodiment. It will beunderstood that this example is merely illustrative and not limiting ofthe present manufacturing process and/or SIL lens.

EXAMPLE 1

To create the mold of the SIL, a 150 microns radius micro sphere (Rubyball lenses, Edmund industrial optics) is used.

The material from which the mold is to be formed (in this case silicon)is preferably prepared a maximum of 4 hours before use, completemanufacturing takes about this amount of time so the silicon is mixedimmediately before beginning. To prepare 30 grams of 10:1 silicon, mixthe two components (27 grams of GE RTV 615A and 3 grams of GE RTV 615B)and use an Eyence Hybrid Mixer (mix for 1 minute and defoam for 2minutes). If some bubbles appear when pouring RTV, it's helpful todefoam again for 1 or 2 minutes.

A 1 mm substrate is used and is cleaned by putting it on a spin coaterat 1000 RPM and flushing it with acetone for 1 minute. The size of thesubstrate is not especially critical, but the use of a plastic dishshould be avoided because it's not flat enough.

To make a first layer of RTV, pour fresh RTV on the substrate locked bya vacuum. Completely cover the substrate and remove the bubbles with awood tongue depressor. Then, launch the spin coater at 700 RPM for 1minute, with two ramps of 15 seconds. After spinning, place the coverslip in a covered petri dish and bake for 3 minutes at 80° C.

The substrate is then taken out of the oven and is cooled for 2 minutes,then put back into the spin coater. Pour a new amount of uncured RTV,then spin at 700 RPM for 1 minute, with two ramp of 15 seconds: thiswill create a 30 microns thick layer which is used to calibrate thecovering effect. It's the minimum thickness to completely cover a moldcore (radius 150 microns) with uncured RTV/Sylgard®.

The calibration curve of FIG. 12B is then used to determine the timeperiod for the pre-curing process based upon the desired height of thelayer.

After these two minutes, work as quickly as possible: handle one moldcore (ruby ball of radius=150 microns), previously cleaned withisopropanol and treated with TMCS for one minute and release it in themiddle of the substrate. The tweezers should not touch uncured RTV, evenif the ball sticks to the tweezers, otherwise the cover effect will bedeeply modified and no longer symmetric. It may be advantageous to usetwo dry tweezers washed with acetone (put them in the oven for a fewminutes). Place the substrate back in the oven and then heat for 45minutes.

Take the substrate out of the oven and let it cool down for 2 minutes,then operate under a microscope (30× is recommended). The use of verysharp tweezers is not a preferred tool, as it will scratch the surfaceof the mold. Flat tweezers are better tools because they do not damagethe mold. The mold core is removed using this tool.

Clean the mold of any dust and remnants of silicon with isopropanol andthen acetone, and the mold is then placed in the oven for a few minutes,then transfer the mold on the substrate into the plasma treatmentmachine. Burn in oxygen plasma for 2 minutes.

The substrate is then placed in a petri dish, at 1 cm from the bottom ofthe dish using a wood tongue depressor, and an excess of silicon ispoured in. The bottom of the substrate should be free from any silicon.It's very difficult to fill the hole with silicon without using vacuum,so the petri dish has to be placed in the degassing machine for anaverage of 20 minutes. All the bubbles should disappear from the surfaceof the mold. The substrate is placed into the spin coater and spun at700 RPM for 1 minute, with two ramps of 15 seconds: this will create aflat surface, with the right thickness for the lens. The substrate isthen placed in a new petri dish and cooked for 45 minutes at 80° C.

The new layer is carefully peeled from the mold. For example, a scalpelcan be used to cut all around the cover slip from the top to thesubstrate, and the silicon borders are removed from the substrate. Makea light scratch in the new layer, far from the lens, and try to insertflat tweezers into that scratch: they will lift the new layer. Then liftthis layer on both sides of the cover slip, and stretch it around thelens; the round surface will leave the hole and stay with the layer,which makes it easier to handle and then to use. In this manner, anexemplary SIL lens structure 300 may be made.

In yet another embodiment, a lens of a different type is illustrated inFIG. 17 and generally indicated at 400. The lens 400 is of a type thatis often referred to as being of a meniscus type as it includes a convexsurface on one side and a concave surface on the opposite side. The lens400 has some properties that are similar to those properties of the SILstructure 300, i.e., hemispherical shape and improved efficiency inlight collection and focusing, and the lens 400 finds particular use asa complementary lens to be used with the SIL structure 300. The lens 400includes a lens portion 410 having an index of refraction n_(s) and anintegral body portion 420. The lens portion 410 is disposed at a highestheight h₄ above an upper surface 422 of the body portion 420.

The lens portion 410 of the lens 400 has a first surface 425 of convexshape and an opposing second surface 411 which has a concave shape. Thelens 400 also has a cavity 430 formed in the body portion 420. Thecavity 430 is formed below the lens portion 410 and is alignedtherewith. The cavity 430 has a depth h₅ as measured from a secondsurface 423 of the body portion 420. Depending upon the application, h₅may be from about 10 microns to about 1 cm and in one exemplaryembodiment is about 290 microns. The value of the depth h₅ is a functionof the radius of curvature of the lens received therein and the radiusof curvature of surface 411 and the position of the sample. Preferably,the vertical displacement between the surfaces 411 and 425 is given bythe radius of curvature of the surface 411 divided by the index ofrefraction. In the illustrated embodiment, the cavity 430 is arcuate inshape and generally approaches the shape of a hemisphere.

The meniscus type lens 400 is designed to capture a very large solidangle of illumination (e.g., from about 4.4 steradians to 6.3steradians) and acts to further and more completely redirect light to adetection element (not shown). More specifically, the first and secondlens surfaces 425, 411 of the meniscus type lens 400 are carefullydesigned to provide the aforementioned benefits. The second surface 411is configured so that light from the sample that traverses this lenssurface does not bend (the light is undeviated). The light travelsthrough the lens portion 410 and the first surface 425 is configured sothat the light rays become more deviated as they traverse this lenssurface and enter the medium adjacent the lens portion 410. Thedeviation is such that the light rays are bent (redirected) to have amore vertical, collimated orientation. Such bending of the light causesthe light to be redirected toward the detection element and results inenhancement of the numerical aperture (NA).

The meniscus type lens 400 is particularly tailored to be used incombination with the SIL structure 300 (which acts as an efficientcollector and focuser). In one exemplary embodiment where the SILstructure is used in combination with the lens 400, the meniscus typelens 400 is designed such that the center of the second surface 411marks the location of a virtual image of the sample that is created bylens portion 302 (FIG. 7). Furthermore, the distance from the top of thefirst surface 425 to the virtual image created by the lens portion 302preferably is determined by relation (II). For example and according toone exemplary embodiment, this distance is about 280 microns but mayextend from 10 microns to 1 cm depending upon the precise application.Thus, the lens portion 410 has a shape that approaches a hemisphere to amuch greater degree than is ordinarily obtainable using conventionalfabrication methods and this provides the aforementioned advantages.

A method for producing the lens structure 400 is described withreference to FIGS. 18 through 28A. Referring to FIG. 18, a container440, typically in the form of a shallow dish defining a base wall andfour peripheral upstanding sidewalls provides the housing for a mold. Toproduce the meniscus type lens 400, a mold is formed. To form the mold,a first layer 450 of moldable material from which the mold is to beformed is cast into the container 440. Preferably, the first layer 450is cast to have a uniform thickness by using conventional techniques,such as spin coating.

After casting the first layer 450, a mold core 460 is positioned in thecontainer 440 on the first layer 450 as shown in FIG. 19. In thisembodiment, there is no need for the first layer 450 to be set prior tothe mold core 460 being disposed thereon. In fact, it is permissablethat the mold core 460 seats against the container 440 because the topportion 462 of the mold core is the portion that is used to form themold. The first layer 450 is then set and to minimize the chance ofbonding between the mold and the lens, the first layer 450 is treatedwith an oxygen plasma to form an anti-adhesive layer (not shown).

As with the other embodiments, the mold core 460 is a spherical bead ofuniformly smooth surface and is available in a number of dimensions,including micro sizes. For example, in one embodiment, the mold core 460can have a radius from about 150 microns to about 4.5 mm; however, itwill be understood that the radius is selected in view of the dimensionsof the lens which is to be fabricated and the radius may be less than150 microns or greater than 4.5 mm in some applications.

Referring now to FIG. 20, a second layer 470 of moldable material iscast into the container 440. The thickness of the second layer 470 isnot critical so long as the second layer 470 is of sufficient thicknessso that the second layer 470 has a rigid form. In one exemplaryembodiment, the second layer 470 has a thickness of about 5 mm orgreater. The second layer 470 is then set.

Referring to FIG. 21, once the second layer 470 is set, the second layer470 is removed from the first layer 450 and the mold core 460. A cavity471 is formed in the second layer 450 due to the mold core 460protruding into this second layer 450 prior to it setting. The oxygenplasma treatment facilitates the easy removal of the second layer 470.Preferably, two or more locating holes (not shown) are formed throughthe complete structure (i.e., the overlying first and second layers 450,470) before the removal of the second layer 470. These locating holesare formed in locations remote from the mold core 460. The locatingholes receive locating pins (e.g., stub adapters) for ensuring properregistration of the layers. Other alignment means can be used, such asvisual markers that are embedded in one or more of the molds. Afterseparating the second layer 470 from the rest of the structure, a bottomsurface of the second layer 470 is treated with an oxygen plasma to forman anti-adhesive layer (not shown).

With reference to FIG. 21 and FIG. 22C, one of the parameters of themolding method which is precisely controlled is the distance between thetwo parts of the mold. The spacing is such that a point 473 of thecavity 470 lies a predetermined distance from the object underexamination. In one embodiment, the point 473 is placed a first distancefrom the virtual image that is created by the SIL structure 300 when itis combined with the lens 400 as shown in FIG. 29. This first distanceis equal to r(1+1/n_(s)) from, where r is the radius of the sphericalmold core 460 and n_(s) is the index of refraction. This is the relation(II) previously set forth.

The first part of the mold is the second layer 470 and the second partof the mold is the first layer 450. One method of precisely distancingthe two mold parts from one another is to form a third layer 480 ofknown thickness separate from the other layers. The thickness of thisthird layer 480 is precisely controlled and then an opening 482 ofsufficient dimension is formed in the third layer 480. One method offorming the third layer 480 is illustrated in FIGS. 22A through 22C inwhich in step (A) a moldable material is cast into a container 483 thathas been treated with oxygen plasma to a predetermined thickness to formthe third layer 480; (B) the opening 482 is formed in the third layer480; and (C) the third layer 480 is removed from the container 483 andtreated with oxygen plasma.

Referring to FIG. 23, the third layer 480 is then disposed on the firstlayer 450 such that the mold core 460 is located within the opening 482.The opening 482 is dimensioned so that not only the mold core 460 butalso a section of the first layer 450 surrounding the mold core 460 isexposed through the opening 482. The second layer 470 is then cast ontop of the third layer 480 and locating holes are formed in the thirdlayer 480 such that the locating holes of all three layers are aligned.Locating pins are then preferably reinserted into the locating holes.After placement of the third layer 480 on the first layer 450, thesecond part of the mold is now defined by the combined first and thirdlayers 450, 480. In this manner, a mold for producing the meniscus typelens 400 is produced.

The first, second and third layers 450, 470, 480 may be formed of theaforementioned materials that are suitable for forming the molds of thepreviously described embodiments, e.g., silicon polymers, such asSylgard® or General Electric RTV 615.

Referring to FIG. 24 and FIG. 17, the meniscus type lens 400 is producedby first separating the first part of the mold (second layer 470) fromthe second part of the mold (first and third layers 450, 480). Amoldable material from which the lens portion 410 of the meniscus typelens 400 is to be formed is typically cast onto the second layer 470such that the moldable material fills not only the cavity 471 but alsoan area surrounding the cavity 471. The moldable material is also castonto the first and third layers 450, 480 such that the moldable materialfills the opening 482 of the third layer 480. This moldable materialforms an intermediate layer between the two mold parts.

Referring to FIG. 25, the first and second mold parts are then seatedagainst one another and the locating pins are placed into the locatingholes to ensure proper registration between the first and second moldparts. The complete assembled mold is then heated for a predeterminedperiod of time to ensure that the moldable material forming the meniscustype lens 400 has properly set. After the predetermined period of timehas passed, the assembled mold is removed from the heating apparatus andallowed to cool. The first mold part (second layer 470) is thencarefully removed from the second mold part (first and third layers 450,480), as shown in FIG. 26. The first mold part should be carefullystored as it is reusable.

Next, the third layer 480, including the intermediate layer forming thelens 400, is removed from the first layer 450 of the mold as shown inFIG. 27 and FIG. 28A. Referring to FIG. 28A, the intermediate layer,generally indicated at 485 and which forms the meniscus type lens 400,is then removed from the third layer 480, thereby leaving the thirdlayer 480 to be reused. Once the meniscus type lens 400 is removed fromthe third layer 480, the mold looks identical to that shown in FIG. 23prior to the casting of the moldable material which forms the meniscustype SIL. As shown in FIG. 28B, the intermediate layer 485 thus formsnot only the body portion 420 but also the lens portion 410 of themeniscus type lens 400. In this manner, the body portion 410 isintegrally molded together with the lens portion 410.

As with the other embodiments, the material from which the meniscus typelens 400 is made using the aforementioned mold may be of any suitableoptically clear material that can be cast as a liquid at a temperatureless than the temperature at which the mold is damaged or otherwiseundesirably deformed. Preferably, the lens material is a pliant siliconelastomer and one exemplary material is the silicon elastomer used toform the mold parts (General Electric RTV 615).

It will be appreciated that the profile of the meniscus type lens 400may be varied from the profile illustrated in FIG. 28C using severaltechniques during the molding method. Referring again to FIGS. 18, 19and 28C, prior to subjecting the first layer 450 to the oxygen plasmatreatment and casting the second layer 450 on the first layer 450, theupper surface of the first layer 450 around the mold core 460 can beprofiled. For example, a cutting tool, such as a scalpel, is used to cutthe material of the first layer 450 around the mold core 460 so as toalter the surface profile of the first layer 450 around the mold core460. FIG. 28C illustrates one exemplary profile for an meniscus typelens 400′ that is obtained by cutting the first layer 450 in selectlocations. By precisely cutting the first layer 450 around the mold core460 (FIG. 19), the shape of the later formed lens is controlled withprecision. FIG. 28C illustrates the meniscus type lens 400″ used incombination with SIL structure 300.

The following example illustrates one exemplary process for producingthe meniscus type lens 400 according to one embodiment. It will beunderstood that this example is merely illustrative and not limiting ofthe present manufacturing process and/or the lens 400.

EXAMPLE 2

To create one exemplary mold of the meniscus type lens 400, a 395-micronradius micro sphere (“bead”) is used (Ruby ball lenses, Edmundindustrial optics). This size is very close to the minimum size of about360 microns needed to cover the SIL of Example 1.

In a large petri dish, the amount of silicon needed is poured; thethickness of the layer has to be exactly about 280 microns in order toachieve the correct height using this size bead. The silicon is pouredin the center of the petri dish, and then spin the petri dish at 300 RPMuntil the silicon meets the borders of the petri dish.

The dish is placed in an oven for a few minutes (5-6 min) before puttingin the bead. It's better to treat the bead with TMCS, and then to cleanit with acetone before releasing it in the middle of the petri dish. Thedish is then placed in the oven at 80° C. for 45 minutes.

There is no need for a layer of cured silicon under the bead, it can lieon the bottom of the petri dish because we just use the top of the bead.The silicon behaves as described before around the top of the bead, butsince we use a large surface, the average thickness of the layer is 280microns:

The petri dish is taken out of the oven, and is cooled for a fewminutes. Then treat it with oxygen plasma for 2 minutes and pour somenew silicon. The thickness of this new layer doesn't need to beperfectly known, it just has to be thick enough to be rigid; preferablythe layer is at least about 5 mm thick. The use of the degassing machineis preferred to prevent micro-bubbles that can appear during curing. Thedish is heated for at least 1 hour, then it is cooled.

Before peeling the new layer, in order to align the two parts of themold, it's very useful to punch two holes into the complete device, farfrom the bead. (The use of Luer Stub Adapter makes this operationeasier).

Silicon shrinks when it's cured, so take both layers out of the petridish before peeling (the two parts will shrink together). Take the upperlayer and treat it with oxygen plasma for 2 minutes.

One parameter to control exactly is the distance between the two partsof the mold; the most convenient way to achieve this is to make a layerwith the right thickness, and then cut a hold. To obtain a 280-micronlayer, pour the fresh silicon exactly in the center of the petri dish,and then spin at 300 RPM until the silicon joins the borders. Treat thislayer with oxygen plasma for 2 minutes, then put it between the twoparts, press and put back the Stub Adapter to punch holes in the rightplace.

On both sides of the mold, separately, pour an excess of fresh silicon.Use the degassing machine to take the bubbles out of the hole of theupper layer.

Put the two pieces together, press and put back the two Stub Adapter.Put a heavy piece of metal on top of the assembly and put in the ovenfor at least 1 hour and 30 minutes.

The petri dish is taken out of the oven, cooled and then the StubAdapter are taken out of the assembly.

Peel carefully the upper layer and keep it clean, it's perfectlyreusable.

Peel the middle layer then take the lens out of this layer so that thelayer can be used again. In this manner the mold is formed.

The advantages of the present molding method are that lens portion 410is much closer to a hemispherical shape than was otherwise ordinarilyobtainable using conventional fabrication methods. This results in thelens 400 having improved light collection properties and also improvedlight focusing properties.

Referring to FIG. 7 and FIG. 17, the SIL structure 300 may be used inthe same applications that were mentioned with respect to the SILstructure 50. For example, the SIL structure 300 may be used inconventional imaging systems, including miniature microscopeapplications and the SIL structure 300 may further be used in lightcollection systems, such as a cytometer or a highly efficientspectrometer. A further application for the SIL structure 300 is in theform of arrays of lenses to enhance fluorescence detection, associatedwith screening micro-arrays. These arrays can be used to improvecollection efficiency for CCDs. Because the SIL structure 300 acts notonly as an efficient collector of light but also as an efficient meansfor concentrating and focusing light, its potential applications arewidespread.

The meniscus type lens 400 may be used by itself in a number ofapplications including all of the potential applications listed abovewith reference to the SIL structures 300 and 50. In addition, becausethe meniscus type lens 400 is not a “contact” lens due to the lensportion 410 not being in contact with a surface, the meniscus type lens400 maintains magnification properties and also increases the numericalaperture (NA). However, the user is not compelled to place the lens incontact with the surface and therefore the lens portion 410 of themeniscus type lens 400 is easy to move relative to the surface. Thischaracteristic can be very useful for: (1) CD burners and data storagein general because there is not evanescent-wave coupling between thelens and the media; and (2) surface inspection with high-resolution.Other potential uses for the meniscus type lens 400 by itself includethose applications that take advantage of the fact the meniscus typelens 400 is a similar to an SIL structure having an empty space inside(the cavity formed in the body portion underneath the lens portion).This structure can be useful to reduce the angular spread of light beamsemanating from lamps, LED, etc.

Referring to FIG. 29, in one exemplary application, the meniscus typelens 400 is combined with the SIL 300 in an imaging system, such as aminiature microscope. In this arrangement, the meniscus type lens 400 ispositioned above the SIL 300 so that the lens portion 302 of the SIL 300is positioned within the cavity 430 of the meniscus type lens 400without an upper portion 311 of the lens portion 302 contacting anyportion of the wall forming the cavity 430. The distance between upperportion 311 and the lower face of lens 400 is controlled by distance d₂.A preferred embodiment is that d₂ is greater than zero so the lenses arenot in contact.

It will be appreciated that the lower surface 423 of the body portion420 of the meniscus type lens 400 can be arranged so that it seatsagainst the upper surface 304 of the body portion 306 of the SILstructure 300 as shown in FIG. 29. The two lens structures 300, 400 canbe attached to one another using any number of conventional techniquesso long as they are suitable. For example, the lower surface 423 may bebonded (e.g., plasma bonding or off ratio combination) to the uppersurface 304. It will be understood that other techniques promoting abond or the like between the two lens structures may be used. Becausethe lens structures 300, 400 are formed of a pliant elastomer material,they may be easily integrally attached to a housing of an imagingsystem, light detection system, etc.

It will be appreciated that there are a wide range of applications for asystem using the SIL lens structure/meniscus type lens combination. Forexample, this combination demagnifies an incident spot of light by afactor of 4 due to its optical properties. This characteristic can beexploited to improve the performances of CD burners and/or data storageand have utility in photolithography applications. The lens combinationalso significantly improves the light collection available with simpleoptical elements in a very cost effective production process and at lowmaterial costs. For example, one application is arrays with collectionoptics that send light to infinity. The array can be screened with asimple optical apparatus that doesn't require a precise positioningalong a vertical axis. The mobile head that reads the fluorescence forexample can be lighter than conventional apparatuses.

Other potential applications using the SIL structure 300 combined withthe meniscus type lens 400 include the following: (1) a cell sorter andother applications that need a fluorescence detection or even just lightdetection; (2) a microscope that is micro-sized so that it can be placedon the top of an optical fiber; in addition, an endoscope can bedesigned to include an integrated microscope; and in general the lensescan be arranged such that they allow detection and function as amicroscope in places unreachable with conventional microscopes; (3)microspectrophotometer with integration of a grating/prism; (4) a systemthat measures the coefficient of diffusion in liquids with a highprecision; furthermore, by using a technique called fluorescence recoverafter photobleaching, the exact size of particles diffusing in a liquidcan be determined and perhaps the affinities between proteins can becalculated; (4) an efficient confocal microscope; (5) using evanescentwaves (created by prism, through the objective or using a stretchedoptical fiber), single molecule detection may be possible; and (6) thecombination of techniques such as fluorescence recovery spectroscopy andevanescent waves can lead to a very efficient inspection of liquidmedias: molecules near surfaces, concentration and interaction with asurface carrying other molecules; moreover, a chip can be designed toscreen the interactions and automate drug affinity characterization.

Referring now to FIG. 30, an exemplary imaging system 1000 is shown. Theexemplary imaging system 1000 is in the form of miniature microscopethat has a housing 800 in which the plurality of lenses are located in apredetermined order and with predetermined spacing therebetween.Preferably, the lenses are integrally connected to the housing 800 so asto form a monolithic miniature microscope structure. According to oneexemplary intended use, the miniature microscope 1000 is designed tohave small dimensions, e.g., a length on the order of about 10 cm. At afirst end 810 of the housing 800 is a light source 820, such as a laseror LED. The light source 820 emits light having a predeterminedwavelength. At an opposite end 830, an image detector 840, such as a CCDcamera, is provided for sensing a magnified, focused image that isproduced as the light passes through the various lenses that aredisposed between the light source 820 and the image detector 840.

The various types of lenses that are used in the miniature microscope1000 are discussed in turn below.

The system includes the meniscus type lens 400 in combination with theSIL structure 300. The arrangement between the lens 400 and the SILstructure 300 is preferably the same as that described in detail withrespect to FIG. 29. The miniature microscope also includes a lens 600which is disposed below the SIL structure 300 and more particularlybelow the observation region 310. Lens 600 is aligned with respect toSIL lens structure 300 so that it focuses light onto a select area ofthe SIL lens structure 300. In one exemplary embodiment, the lens 600 isa solid immersion lens (SIL) 600 of the condenser. In other words, it isof an SIL structure and acts to focus light on the sample in theobservation region 310. The lens 600 may be manufactured and positionedin the illustrated location using several different techniques. Forexample, the lens 600 can be manufactured using a method similar to theone described hereinbefore with reference to FIGS. 2 through 4. Afterforming the lens 600 using one of the disclosed molding methods, thelens 600 can then be integrally connected to the SIL structure 300 usinga suitable technique, such as plasma bonding or off ratio combination.It will be appreciated that the dimensions of the lens 600 are greaterthan the dimensions of the SIL structure 300 due to the function of thelens 600 in the system 1000.

The exemplary miniature microscope 1000 shown in FIG. 30 also includes aplurality of ordinary lenses which are generally indicated at 700, 701,702, 703, 704. The precise number and shapes of the ordinary lenses willvary from application to application. The ordinary lenses may beproduced using a molding method similar to the molding method used toproduce the SIL structure 50 of FIG. 1 with the molds being specificallycontoured and the process tailored to form a lens having particulardimensions and shape. The molding process of the present invention canbe tailored to produce lenses that have different lenses surfaces. Amethod for producing an ordinary lens, such as the ordinary lenses700-704, is described with reference to FIGS. 31 through 37. Referringto FIG. 31, a container 710, e.g., a shallow dish, provides the housingfor the mold. To produce any one of the ordinary lenses 700, arespective mold is formed.

To form the mold, a first layer 720 of moldable material (e.g., GeneralElectric RTV 615) is cast into the container 710. The thickness of thefirst layer 720 is determined beforehand based upon a number of factors,including the radius of the lens 700. A mold core 730 (e.g., a ballbearing) is positioned within the first layer 720 as shown in FIG. 32.The dimensions of the mold core 730 in this embodiment are much greaterthan the dimensions of the mold cores used to form the micro-size SILstructures described hereinbefore. For example, the mold core 730 mayhave a radius as large as 1 cm. Because the mold core 730 is typicallynot micro-size, the covering effect of the material on the mold core 730due to surface tension is not as critical in this embodiment because ofthe increased dimensions of the mold core 730. The first layer 720 isthen set.

Referring to FIG. 33 once the first layer 720 is set, the mold core 730is removed and the first layer 720 is treated with oxygen plasma. Themold core 730 is then inserted back into the cavity that it formed inthe first layer 720. A second layer 740 is cast onto the first layer 720including over the mold core 730. The thickness of the second layer 740is preferably at least about 0.5 cm. The second layer 740 is then set.

Once the second layer 740 has set, the second layer 740 is removed asshown in FIG. 34. The second layer 740 is a first part of the mold usedto form the ordinary lens 700. The removed second layer 740 has a cavity747 formed therein which results from the material of the second layer740 flowing around the mold core 730. The formation of the rest of themold depends upon what type of lens 700 is to be formed. Morespecifically, the method will differ depending upon whether the lens 700is classified as a plano-convex lens or a convex lens.

To manufacture a plano-convex lens, only one spherical mold is needed.Therefore after treating the second layer 740 (the mold) with oxygenplasma, the mold is placed upside down in a container, such as container710. A moldable material from which the lens is to be formed is castonto the upwards facing surface (the surface having the cavity 747) ofthe second layer 740. The moldable material is a suitable opticallyclear material, such as those mentioned hereinbefore. The moldablematerial leaves the upwards facing surface of the mold and collect inthe bottom of the container and the upper surface will be almost flat.At the same time, the moldable material is maintained in the cavity 747as this material serves to form the lens. To improve its flatness it ispossible to spin the container slowly being careful not to take too muchof the moldable material out of the cavity formed in the second layer740. The moldable material is then set and then subsequently removedfrom the mold (second layer 740).

For convex lenses, two separate identical molds are needed. Thus, afterforming the first mold (second layer 740) by casting this layer onto thefirst layer 720, setting and then removing the second layer 740, themethod is repeated to form the second mold. In other words, additionalmoldable material forming the second layer 740 is cast onto the firstlayer 720, set and then removed to form the second mold. It has beendiscovered that it is more advantageous that the two molds are formedusing the same part (i.e., the same first layer 720 and same mold core730, to ensure that the two molds have essentially identical dimensionsand profiles. FIG. 35 illustrates the two molds 740 spaced from oneanother in facing arrangement. The two molds 740 are each treated withoxygen plasma.

The two molds 740 should then be aligned with respect to one anotherusing a high degree of precision. For example, the two molds 740 may bealigned under a microscope. Locating holes (not shown) are preferablyformed through both molds 740 when the two molds 740 are seated againstone another. Both molds 740 are first placed upside down in a container(such as container 710 of FIG. 31). Moldable material from which theconvex lens 700 is to be formed is cast onto the upwards facing surfacesof the two molds 740 such that the moldable material fills not only eachcavity 747 but also flows on the surfaces surrounding each cavity 747.One of the molds 740 is then placed on top of the other mold 740 withthe cavities 747 being aligned and facing one another as shown in FIG.36. Furthermore, the locating holes of each mold 740 are aligned andlocating tools, such as locating pins, are inserted into the locatingholes so as to ensure proper alignment between the two molds 740. Themoldable material that forms the lens 700 is then set. The time periodfor this setting process should ensure that the curing heat hassufficient time to get to the middle of the assembled mold and heat andset the moldable material.

Referring to FIG. 37, the upper mold 740 is first removed and then thelayer including the lens 700 is removed. This molding method results inthe formation of lens 700 of convex design.

The molds 740 are reusable and additional lenses 700 having the samedimensions may be produced by simply repeating the steps illustrated inFIGS. 36 and 37. It will be appreciated that one complete mold producesone lens having a distinct shape and specific characteristics.Therefore, a number of molds may be formed according to the above methodso as to provide molds designed to produce alternative shapes and sizedfor these lenses. The shapes, dimensions, and specific location of theordinary lenses within the housing 800 will vary from application toapplication.

It will be appreciated that the molding methods disclosed herein may bemodified and tailored to produce lenses having any number of shapes andsizes. FIGS. 38 through 43 illustrate an alternative method for forminga lens having a predetermined shape and size. For purpose ofillustration only, the method will be described with respect to theformation of a mold for producing a plano-convex lens. Referring to FIG.38, a container 605, typically in the form of a shallow dish, provides ahousing for the mold. To produce a piano-convex lens, such as lens 702,a buffer layer 610 is preferable cast onto the container 605. The bufferlayer 605 is formed of any number of pliant materials, including pliantsilicon elastomers. A first layer 620 of moldable material from whichthe mold is to be formed is cast into the container 605 on top of thelayer 610. Preferably, the first layer 620 is cast to have a uniformthickness. After casting the first layer 620, a mold core 630 ispositioned in the container 605 on the first layer 620 as shown in FIG.39. The mold core 630 is actually a lens of predetermined shape anddimension and in this embodiment, the mold core 630 is a plano-convexglass lens because the mold is designed to produce a plano-convex lensformed of a pliant elastomer. The layer 610 should be of sufficientthickness so that it prevents the mold core 630 from contacting thecontainer 605.

The initial thickness of the first layer 620 is selected in view of thedimensions of the mold core 630 so that the first layer 620 is formed toa height up to the point of the maximum dimension (e.g., diameter) ofthe mold core 630. In this instance and for the case of a mold core 630in the form of a plano-convex lens, the convex surface faces the bottomof the container 605 and therefore, the first layer 620 is formed up tothe piano portion of the mold core 630. The top surface of the firstlayer 620 thus defines a planar surface as shown in FIG. 39. The firstlayer 620 is allowed to set. Next as shown in FIG. 40, the lens moldcore 630 is removed and the first layer 620 is treated with oxygenplasma. The lens mold core 630 defines a cavity 621 in the first layer620. The formed first layer 620 comprises a first part of the mold.

Referring to FIG. 41, the lens mold core 630 is repositioned in thecavity 621 and a second layer 640 of moldable material is cast onto theupper surface of the first layer 620 and the top surface of the lensmold core 630. The second layer 640 is cast to a predetermined thicknessand then is allowed to set. Referring to FIG. 42, the second layer 640comprises a second part of the mold and once the second layer 640 sets,the second layer 640 is removed and the lower surface thereof is treatedwith oxygen plasma. The lens mold core 630 is removed from the cavity621 and then a moldable material 650 from which the lens 702 is formedis cast into the cavity 621 (first part of the mold) and then the secondpart of the mold (the second layer 640) is placed over the moldablematerial 650 that has been cast as a layer. The moldable material 650 isthen set. Once, the moldable material 650 forming the lens sets, thesecond layer 640 is then removed and the lens 702 is removed from thecavity 621 as shown in FIG. 43.

It will be appreciated that the second part of the mold, namely thesecond layer 640, can be configured to have any number of shapes. Inthis embodiment, the second layer 640 has a planar lower surface;however, the lower surface can have other configurations, such as aconvex or concave design. The above molding method is therefore readilyadaptable to form a number of different types of lenses having a widerange of dimensions and shapes.

Exemplary materials used to form the first and second layers 620, 640and include the silicone elastomers disclosed previously herein. Themoldable material 650 from which the lens 702 is formed can be of thesame type of material as the layers 620, 640 so long as it is a suitableoptical material.

In the exemplary embodiment of FIG. 30, the lenses 700, 701, 600 aredisposed between the light source 820 and the SIL structure 300, whilethe lenses 704, 702, 703 are disposed between the meniscus type lens 400and the image detector 840. The first set of lenses 700, 701, 600 servesto focus the light to a spot in the sample chamber 310. For example, thelens 700 collects and collimates light from the LED 820, and the lens701 refocuses the light onto the lens 704. The lens 600 is of the typethat acts as a concentrator of light in that it collects and focuses thelight to the sample chamber 310. In this exemplary embodiment, the lens600 is of a solid immersion lens type; however, the lens 600 may be ofany type so long as it has the aforementioned focusing characteristics.One advantage of having the lens 600 be an SIL lens structure formedusing one of the methods disclosed herein is that its ability to collectand concentrate/focus the light from the LED 820 to the sample isimproved compared to conventional lenses. When the lens 600 is of an SILtype lens, it can be made separately from the SIL structure 300 and thenattached thereto by a suitable process, such as plasma bonding.

In the lens arrangement of the miniature microscope 1000, the SILstructure 300 acts as an efficient collector of light that is emitted(reflected) from the illuminated sample. The meniscus type lens 400enhances the light, as shown in FIG. 44, which is then directed tolenses 704 and 702. Furthermore, lens 400 acts to redirect and deviatethe light towards the detector 840. Lenses 704 and 702 act to collimatethe light as shown in the ray diagram of FIG. 45 and then lens 703collects the collimated light and focuses the image as magnified onto animage sensor (e.g., a CCD array) of the detector 840. The relativepositioning of the lens 703 and the image sensor determines the focus ofthe image. Other microscope configurations can be employed as suggestedby this configuration.

One advantage of the molding methods described herein is that the moldscan be formed with great precision in a range from micro-size to largerconventional lens sizes and are reusable, thereby permitting many lensesto be formed using a single mold. Conventional lenses are able to beeasily and cost effectively manufactured using one of the disclosedmolding methods. The manufacturing costs that can be saved using thepresent molding methods as compared to conventional lens making methodsis significant. These savings permit the lenses to be producedinexpensively, while at the same time maintaining the precision and highquality of the lenses.

The lenses may be configured to have any number of different shapes,such as converging lenses (piano-convex and biconvex) or divulginglenses (plano-concave or biconcave), etc. As one can appreciate lenseshaving conventional shapes are used in a variety of applications,including goggles, swimming pool glasses, other types of glasses,magnifiers, products have magnifying elements incorporated therein, etc.Because the lenses are preferably formed of a pliant silicon elastomer,additional advantages are provided due to the “soft” optics nature ofthese products. One such advantage is that the lenses will not shattersuch as optics made from glass.

In addition, the method described above with reference to FIGS. 31through 37 may be used to make lenses having shapes like Fresnel lenses.This type of lens has a rather large size; however, the thickness is notgreat. Fresnel type lenses can be used in a variety of applications. Forexample, a diverging Fresnel lens product is commercially available andis intended to be positioned on the back window of a vehicle. Becausethis is a “soft” lens, it can be applied to surfaces, such as the backwindow of the vehicle, without adhesives. It is therefore easily removedfrom the applied surface.

The ability to produce conventional lenses of any shape in a costeffective manner is attractive to manufacturers of a wide array ofproducts. For example, many toy producers have product lines thatincorporate some type of conventional lens into the product. Theseproducts range from simple beginner microscopes and simple goggles tomore complex optical containing products. The present lens manufacturingmethods can be used to produce complex optical components, such ascamera/video objectives. In addition, it is possible to realizeswitchable objectives for disposable cameras even those having wideangles. Currently, the disposable cameras that are commerciallyavailable are not entirely disposable as the objectives of the cameraare typically reused. Using elastomeric lenses not only reduces the costof the product but also makes the product completely disposable.Moreover, the ability to produce objectives for panoramic pictures atreasonable prices is very appealing.

Other application areas for these lenses manufactured according to thepresent methods are in areas such as scanners or video/retroprojectorsthat are very expensive and may suffer from the cost of the opticalelements used. For example, this includes the very large lenses that areused for a videoprojector.

Referring now to FIG. 46, one exemplary use of an optical systemincorporating the SIL structure 300 by itself or in combination with themeniscus type lens 400 is in an integrated imaging system, such as theminiature microscope 1000 that forms a part of an integrated micro-sizedworkstation 1100, e.g., a microfluidic device or chip. For purpose ofillustration only, the miniature microscope of FIG. 46 is the same onethat is described in detail with reference to FIG. 30. However, only theupper portion of the miniature microscope 1000 above the SIL structure300 is shown in FIG. 46. It will be appreciated that the bottom portion,i.e., the portion below the SIL structure 300, is not shown but liesbeneath the microfluidic chip 1100. Because the microfluidic chip 1100and the SIL structure 300 can be formed of the same materials, it willbe appreciated that the SIL structure 300, along with other componentsof the miniature microscope 1000, can be integrally formed as part ofthe microfluidic chip 1100.

In the illustrated embodiment, the microfluidic chip 1100 has a numberof channels 1110 formed in an upper surface 1120 thereof. The integratedmicro-sized microscope 1000 is selectively positioned on the uppersurface 1120; however, for purpose of illustration only the size of themicroscope 1000 has been exaggerated. Some of the details of themicrofluidic chip 1100 have also been exaggerated for purposes ofillustrating how the microscope 1000 is used in combination with themicrofluidic chip 1100 according to this exemplary application. In oneexemplary embodiment, the SIL 300 has a lens portion with a 150 micronsradius and the total height of the microscope 1000 is about 10 cm.

One or more of the channels 1130 carry a sample to be analyzed and themicroscope 1000 is aligned with at least one of these channels 1130 fordetection of the sample. Accordingly, the SIL 300 is aligned withrespect to the channel 1130 carrying the sample. Experiments are thencarried out on the microfluidic chip 1130 in a conventional manner byoperating the imaging system 1000 in a traditional manner.

The integrated microscope 1000 is positioned on the upper surface 1120using any number of suitable techniques designed for placement andalignment of objects according to a micro scale. For example, theintegrated microscope 1000 may be attached to the upper surface 1120 byusing tweezers under microscope observation, whereby the SIL structure300 is aligned with respect to the sample area of interest. Oncealigned, the SIL structure 300 is bonded or otherwise attached to theupper surface 1120. For example, it can be bonded by plasma treatment oroff ratio elastomer combination. Following the placement of the SILstructure 300, the meniscus type lens 400 is applied in the same manner.In other words, the meniscus type lens 400 is aligned with the SIL 300and then attached thereto, thereby ensuring optical alignment.Alternatively, the meniscus type lens 400 may be aligned with andattached to the SIL 300 to form a single integrated structure which isthen positioned and attached to the upper surface 1120 in the mannerdescribed above. The other components of the integrated microscope 1000can be properly positioned and attached using these same techniques.

Advantageously, the use of the SIL lens structure 300 improves theimaging performance of the microscope and this performance is furtherenhanced by using the meniscus type lens 400 in combination with the SILlens structure 300. For example, the microfluidic chip 1100 can be usedin experiments for detection and sorting of cells which are on the orderof 2 microns long and 1 micron large. Using ordinary imaging deviceshaving lower NA values, the cells are not visible even when the power ofthe light source (e.g., LED) is increased. Thus, without a high NAaperture microscope, no sorting can be achieved. When the SIL lensstructure 300 is used, the cells appear clearly; however the signal isstill weak enough to prevent an efficient sorting due to noise of theCMOS. The meniscus type lens 400 is used for increasing the intensitycollected. By adding the meniscus type lens 400, the cells are magnifiedby a factor of about 2 and the cells have sufficient intensity thatpermits them to be sorted. The electric signal coming out of the CMOScan be analyzed.

In sum, the SIL lens structure 300 by itself or in combination with themeniscus type lens 400 provides optical coupling to devices or sampleswithin microfluidic or microelectronic chips or devices, such at thechip 1100, at higher efficiencies and lower cost than which isachievable with conventional techniques while at the same time reducingthe mechanical complexity of the instrument portion of the device.Integrated lenses provide the opportunity to achieve lower instrumentcost by eliminating the need for expensive conventional high numericalaperture (NA) objective lenses while greatly simplifying the problem ofalignment of external optical systems to microfabricated devices, suchas channels, cavities, sample wells, optical-sources, and detectors.Optical alignment is simplified because the optical beam diameteremerging from an integrated optic is much larger than actual detectionand is related to the light collection ability (or NA) of the integratedoptical element(s). Alignment tolerance will necessarily be related to apercentage of the emerging beam diameter for an integrated optic or theactual sample size for an externally aligned optical system.

An SIL or mensicus type combination lens provides high numericalaperture (NA) to and from an electro-optic device fabricated within asemiconductor or microfluidics chip or any other suitable structurecapable of incorporating optical sources and detectors, such as LEDs,laser diodes, photodiodes, avalanche photodiodes, or any other type oflight source or detector. High numerical aperture (NA) coupling isbeneficial for coupling light from samples since the collectionefficiency is proportional to NA⁴ for fluorescence detection and NA² forluminescence detection.

The SIL structure 300 and/or the meniscus type lens 400 (or an array ofsuch lenses) as described previously herein can be fabricated in aplanar layer which is bonded to a surface. Alignment marks or featurescan be fabricated in the same layer as the lens and be optically ormechanically aligned to optical or mechanical features on the surface.Precise optical alignment is required when the source of light ordetector is small, such as a small sample volume contained within amicrofluidics detection region residing within a microfabricated channelor small integrated LED residing in a microelectronic chip.

When fabricating devices with soft materials, such as plastics orelastomers, significant distortions on a global scale can result due tomaterial non-uniformities and other non-uniformities and strains whichmight occur as a result of the manufacturing process. The use of globalalignment marks may not result in the level of precision needed foralignment of lenses to small targets. Since precise alignment can easilybe maintained over short distances using local alignment marks, it maybe desirable to break large lens arrays on a single chip or lens arrayscovering multiple chips on a large wafer into smaller sub-arrays.Aligning a separate lens array or sub-array to each chip on a wafer,with local alignment, can maintain precise alignment despite largedistortions on a global scale.

A SIL structure 300 with or without the meniscus type lens 400 canprovide high numeral aperture (NA) optical coupling to and from a samplecontained in a microfabricated structure, such as a channel, cavity,well, or device fabricated within a microfluidic chip. These lenses or alens array can be either integrated into the structure of the chip or beincorporated into the chip reading instrument. If incorporated into theinstrument, means must be provided to position the chip so as to bringthe lens array into proper alignment (in X, Y, Z) with the array ofdetection sites prior to reading. Light from the lens array can becoupled into a CCD or an array of CCDs to allow simultaneous reading ofall detection zones in the chip. This optimizes the number of photonsthat can be collected in the shortest measurement time and allowedinformation to be simultaneously collected from spatially separatedregions on the chip. A optically dispersive element such as a gratingcan be included in the optical path to allow spectral discrimination orsimultaneous measurements at multiple wavelengths, Means can be providedto incorporate total internal reflection measurements as well as surfaceplasmon resonance measurements.

While integrating the lens array into the chip optimizes the numericalaperture, simplifies the mechanics of the instrument, and reduces theneed for precise opto-mechanical alignment between the chip and theinstrument, extra cost is added to the disposable chip. This extra costscan add up to significant amounts when large numbers of chips are usedfor screening application or other similar applications. Alternatively,if the lens array is incorporated into the instrument, the numericalaperture (NA) will be lower but the cost of the instrument will still belower than what it otherwise would be if conventional optics were usedinstead of the SIL lens structure 300, meniscus type lens 400, or acombination thereof. An instrument designed using SIL or meniscus typelens combination lens arrays, offers significant performance advantagesover conventionally designed instruments. Such a lens system facilitatesoptical coupling to a CCD which is capable of simultaneously observingmultiple detection regions.

In yet another embodiment, an array of SIL lenses is provided and amethod of manufacturing the array is described with reference to FIGS.47 through 53. Referring to FIG. 47, a planar substrate 1300 made of asuitable rigid material is provided. In an exemplary embodiment, thesubstrate 1300 is a silicon wafer on which a photoresist layer 1310 ofpredetermined thickness is provided. One preferred thickness for thephotoresist layer 1310 in the fabrication of the array of SIL lensessatisfies the relation (v) H>=r(1−1/n)+h₂, where r is the radius of themold core 1320 (FIG. 49), n is the index of refraction of the materialwhich forms the finished optical element, and h₂ is the thickness of thebody portion as shown in FIG. 7. Using standard lithography procedures,wells 1330 of predetermined diameter D are defined in the photoresistlayer 1310 as shown in FIG. 48. The wells 1330 are formed according toany number of predetermined patterns. One preferred diameter D satisfiesthe relation (VI) D=2×r×sin(arcos(1/n−h₂/r).

Referring to FIG. 49, mold cores 1320 are then set into the wells 1330.The mold cores 1320 can be formed of sapphire, ruby, or steel and are inthe form of spheres. The mold cores 1320 rest on the substrate 1300 withthe photoresist layer 1310 contacting the mold cores 1320 at selectpoints. The exposed surfaces of the mold cores 1320 and the photoresistlayer 1310 form a well-defined boundary. The greater the mold cores 1320protrude above the photoresist layer 1310, the greater the undercutregions of the mold will be. To form the mold, a moldable material(e.g., silicon elastomer) is cast onto the surface defined by theprotruding mold cores 1320 and the exposed photoresist layer 1310 todefine a first layer 1340 as shown in FIG. 50. Preferably care is takenso that small bubbles are not trapped in crevices at the intersection ofthe mold cores 1320 and the photoresist layer 1310. One preferred methodfor their removal is placing the entire structure into a vacuum forminutes. The thickness of layer 1340 should completely submerge the moldcores 1320 and supply mechanical stiffness. Once the layer 1340 is setby curing, the layer 1340 is removed along with the mold cores 1320 andthe layer 1340 is treated with oxygen plasma. The layer 1340 has aseries of defined cavities 1342.

The mold (first layer 1340) is inverted and a moldable material fromwhich the array of SIL lenses it to be formed is cast onto the firstlayer 1340 so that the moldable material not only fills the cavities1342 but also fills the areas between the cavities 1342 so as to formthe connecting body portion of the array. This moldable material forms asecond layer 1350. In one embodiment, the entire structure is placed ina standard spinner so as to control the thickness of the body portion.FIG. 53 shows the removal of the second layer 1350 from the mold. Thesecond layer 1350 is in the form of an array of SIL lenses havingspherical lens portions 1352 and an integral body portion 1354 extendingtherebetween. The mold can be reused.

A significant advantage of this method of fabrication is that is doesnot require the precise of surface control, since the mold profile willnow conform to the surface defined by the combination of the mold cores1320 and the photoresist layer 1310. This method is applicable toproduction of a regular array of closed spaced lenses such as might benecessary in the production of a CCD array. Additionally, precisionplacement of lenses which have a definite spatial relation among themmay also be used in an application where optical illumination andinterrogation may be necessary in a number of distinct positions on amicrofluidic chip or similar device.

The following example further illustrates the advantages provided by theSIL lens structure 300. It will be understood that the following exampleis merely exemplary and not limiting.

EXAMPLE 3

By using one of the solid immersion lens structures disclosed herein,the numerical aperture (NA) of the optical system may be increased to avalue that is otherwise not obtainable using conventional lenses. FIG.54 illustrates how the NA is increased using a solid immersion lens. Anoptical system 1400 is illustrated and in the exemplary embodiment, thesystem 1400 is a fluorescent microscope arrangement. The set of filtersis chosen according to the dyes used in the different experiments (blueexcitation and green emission). A laser 1410 is used to create theexcitation and in this instance the laser 1410 is a blue laser having awavelength of 488 nm and a beam diameter of 1 mm. A number of companiesmanufacture lasers having these characteristics and one exemplary laser1410 is a Uniphase 2214-10 SL Argon Laser. The excitation may also becreated by a blue LED 1220, e.g., Luxeon Star/C.

The filter set is selected in view of the excitation wavelength (comingfrom the laser 1410 or the blue LED 1420 and allows only the fluorescentemission to be focused on an image detector 1430, such as a CCD camera.The beam of the laser 1410 is increased with first and second lenses1440, 1450, respectively. The lenses 1440, 1450 have a diameter of 1.9cm and focal lengths of −2 cm and 4 cm, respectively. The beam is thenfiltered by an excitation filter 1460 (wavelength of 465 nm to 495 nm)and is reflected by a dichroic filter 1470 towards a lens 1480 thatfocuses the beam on the solid immersion lens 300. It will be appreciatedthat the solid immersion lens 300 is formed according to one of themolding methods disclosed herein. In one exemplary embodiment, the lens1480 has a diameter of 1.9 cm and a focal length of 1.15 cm. The lens1480 is chosen that the initial NA, with the SIL 300, is high (NA=0.65).The blue LED 1420 is arranged so that it is the focal point of a firstlens 1490 (diameter 1.9 cm and focal length 3 cm) so that the excitationis able to filtered by an excitation filter 1500 (wavelength 470 nm to490 nm). A second lens 1510 (diameter 1.9 cm and focal length 1.15 cm)is arranged to focus the rays on the passage (i.e., observation region310 of FIG. 7) under the lens portion of the SIL 300.

FIG. 55 illustrates the excitation wavelength of the above-described setof lenses which is selected to allow only the fluorescent emission to befocused on a CCD camera or the like.

When the SIL structure 300 is put over an RTV chip (not shown) whereflourescent components are flowing inside a channel formed therein andhaving exemplary dimensions of 1 cm length, 20 microns width, and 5microns deep. In this example, the reflective index of the solution isn=1.3 (therefore 1.3 is the largest numerical aperture that can be usedwithout evanescent field).

The SIL structure 300 has to collect as much emission light as possible.This emission light is not reflected by the dichroic filter because thisone reflects the light below 505 nm, but lets green light (beyond 505nm) go through. The emission light is finally filtered by an emissionfilter (515 nm to 555 nm) 1520 and is focused by a lens 1530 (f=17.5 cm)on the CCD camera 1430 (Philips Image Sensor Module FTM 800).

In order to measure the numerical aperture, fluorescent beads(Interfacial Dynamics Corporation 2-FY-1K.2) of diameter 5 microns, anexcitation wavelength of 490 nm, an emission wavelength of 515 nm, aconcentration of 2×10⁸ beads per ml to measure the numerical aperture ofthe SIL structure 300.

A wide range of SILs were used for this experiment, from a 2 mm radiusSIL to a 395 microns radius SIL. There were absolutely no changes in theresults. As shown in FIGS. 56A and 56B, the SIL 300 increases theintensity of the spot as shown in FIG. 56A (with SIL 300) and FIG. 56B(without SIL 300). The profile is measured in gray level, along a linepassing through the centers of the two different beads. The lightintensity of the beads is given by the area of the spot multiplied bythe difference between the average intensity inside the spot and outsidethe spot.

Pictures of the same beads were taken and their place of the device wasdetermined and then the light intensities of the spots was compared.Changing the light intensity of the illumination, permits a widespectrum of initial intensity to be achieved in order to demonstratethat the efficiency of the SIL 300 does not depend on the brightness ofthe objects. FIG. 57 shows the results. The ratio of the intensity withand without the SIL 300 leads to the ratio of the numerical apertureswith and without the SIL 300. The relation (VII) is:NA_(with SIL)/NA_(with SIL)=(Intensity with the SIL/Intensity withoutthe SIL)^(1/4)The average ratio of the two intensities is equal to 13.35+/−0.53 asshown in FIG. 58. The initial numerical aperture, without the SIL, is0.63, so the numerical aperture is NA=1.25+/−0.02. This illustrates theincrease in NA.

While the invention has been particularly shown and described withreference to preferred embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the spirit and scope of theinvention.

1. A method for constructing a solid immersion lens structure, themethod comprising: (a) producing a mold so as to define a pliant lenscavity in which a spherical solid immersion lens portion of the solidimmersion lens structure is to be formed, the pliant lens cavity havingan orifice having a transverse dimension less than a transversedimension of the lens cavity for the spherical solid immersion lensportion, wherein the surface tension of the material from which the moldis formed is controlled so that the pliant lens cavity has apredetermined depth; (b) casting a moldable material, from which atleast the solid immersion lens portion is to be formed, into at leastthe lens cavity; (c) permitting the moldable material to set thereby toform the solid immersion lens portion of the solid immersion lensstructure; and (d) removing the solid immersion lens portion of thesolid immersion lens structure from the pliant mold after the moldablematerial has set.
 2. The method of claim 1, wherein producing the moldcomprises forming the mold from a thermally-resilient deformablematerial.
 3. A method for constructing a solid immersion lens structure,the method comprising: (a) producing a mold so as to define a pliantlens cavity in which a spherical solid immersion lens portion of thesolid immersion lens structure is to be formed, the pliant lens cavityhaving an orifice having a transverse dimension less than a transversedimension of the lens cavity for the spherical solid immersion lensportion; wherein the mold producing step comprises casting a firstcatalyzed crosslinkable liquid around a mold core in the form of agenerally spherical element, the surface tension of the first catalyzedcrosslinkable liquid being controlled by a pre-curing process so thatthe first catalyzed crosslinkable liquid is cast to a height h aroundthe mold core prior to it setting as the mold, thereafter removing moldcore from the mold after the first catalyzed crosslinkable has setwherein a region of the mold adjacent the orifice is allowed totemporarily deform thereby to permit the spherical element to be removedwith minimal damage to the mold; (b) thereafter casting a secondcatalyzed crosslinkable liquid into the mold until it has set; and then(c) removing the solid immersion lens portion from the mold after thesecond catalyzed crosslinkable liquid has set wherein the region of themold adjacent the orifice is allowed to temporarily deform thereby topermit the solid immersion lens portion to be removed.
 4. The method ofclaim 3, wherein the height h is controlled by the relationship:h=r(1+1/n_(s)), where r is the radius of the mold core and n_(s) is theindex of refraction of the material from which the solid immersion lensportion is made.
 5. The method of claim 3, wherein the first catalyzedcrosslinkable material is pre-cured for a time period sufficient tocause the first catalyzed crosslinkable material to assume height haround the mold core when the mold core is positioned in this materialprior to the first catalyzed crosslinkable material setting as the mold.6. A method for constructing a solid immersion lens structure, themethod comprising: producing a mold so as to define a pliant lens cavityin which a spherical solid immersion lens portion of the solid immersionlens structure is to be formed, the pliant lens cavity having an orificehaving a transverse dimension of the lens cavity for the solid immersionlens; wherein the mold producing step comprises casting a first moldablematerial into a container to form a first layer from which the mold isto be formed and permitting the first layer to set, then positioning amold core on the first layer, and then casting the first moldablematerial into the container to at least partially encapsulate the moldcore and assume a circumferential wall height h around the mold core,thereby forming a second layer immediately adjacent the first layer, thefirst moldable material that forms the second layer being pre-curedprior to being cast around the mold core so as to reduce surface tensioncharacteristics of the first moldable material such that the firstmoldable material assumes height h around the mold core.
 7. The methodof claim 6, wherein the height h is controlled by the relationship:h=r(1+1/n_(s)), where r is the radius of the mold core and n_(s) is theindex of refraction of the first moldable material.
 8. The method ofclaim 6, wherein the mold core has a generally spherical shape andprotrudes from an upper surface of the first layer.
 9. The method ofclaim 6, further comprising casting a second moldable material from whatat least the solid immersion lens portion of the solid immersion lensstructure is to be formed into the container to fill not only the lenscavity, but also to form a layer in the container, the layer defining anupper surface above the lens cavity, such that the layer forms a bodyportion of the solid immersion lens structure when the second moldablematerial has set, the body portion then being integrally molded togetherwith the solid immersion lens portion.
 10. A method for constructing alens of a meniscus type, the method comprising: (a) producing a mold soas to define a pliant lens cavity in which a lens portion of themeniscus type lens is to be formed and casting the lens portion of themeniscus lens therefrom; (b) wherein the mold producing step comprises:(c) casting a first moldable material into a container to form a firstlayer from which the mold is to be formed; (d) positioning a mold coreon the first layer prior to the first layer setting so that the firstmoldable material at least partially encapsulates the mold core; (e)casting a second moldable material into the container, thereby forming asecond layer immediately adjacent the first layer, the second layer atleast partially encapsulating a top portion of the mold core so as todefine a first lens cavity in the second layer once the second moldablematerial sets, the first lens cavity at least partially defining thepliant lens cavity; and (f) removing the second layer from the firstlayer and then positioning a spacer layer having a predeterminedthickness on the first layer, the spacer layer having an opening formedtherein for receiving the mold core and a peripheral area of the firstlayer surrounding the mold core, the spacer layer being formed of athird moldable material.
 11. The method of claim 10, wherein the first,second and third moldable materials are the same.
 12. The method ofclaim 10, wherein each of the first, second, and third materials is athermally-resilient deformable material.
 13. The method of claim 10,wherein the lens portion of the meniscus type lens is formed by: castinga fourth moldable material into at least the opening of the spacer layerso as to at least partially encapsulate the mold core and into at leastthe first lens cavity of the second layer, the second layer beingpositioned on the spacer layer and then setting the fourth moldablematerial.
 14. The method of claim 10, wherein the lens portion of themeniscus type lens has a convex surface defined by the first lens cavityformed in the second layer and an opposing concave surface defined bythe mold core protruding above the first layer.
 15. The method of claim10, wherein the first lens cavity has a generally hemispherical shape.